Uvc anti-microbial breathing sterilizing modules, masks and devices

ABSTRACT

The present application for patent is in the field of anti-microbial breathing apparatus. More specifically the present application for patent is in the field of anti-microbial sterilizing modules and apparatus wherein the apparatus comprise a sterilization module which contains UVC, UVA/B, and/or blue light sanitizing radiation emitting components which sterilize the air passing through the sterilizing module to be breathed prior to the air entering the body of the user. The disclosure optionally includes the use of filters, electronically charged screens. fans, and intake and outflow valves.

This application claims priority of the filing date of U.S. ProvisionalPatent Application Ser. No. 62/985,155 filed 4 Mar. 2020, entitled “UVCANTI-MICROBIAL MASK AND MODULES” which application is incorporated byreference herein in its entirety.

FIELD OF INVENTION

The present application for patent is in the field of anti-microbialbreathing apparatus. More specifically the present application forpatent is in the field of anti-microbial sterilizing modules andapparatus wherein the apparatus comprise a sterilization module whichcontains UVC, UVA/B, and/or blue light sanitizing radiation emittingcomponents which sterilize the air passing through the sterilizingmodule to be breathed prior to the air entering the body of the user.

BACKGROUND

Microbial masks utilize filter systems to protect the user from outsidebacteria, virus, and microbes. Currently available filtration-based masksystems range from non-medical cloth masks, to surgical or medical masksto N95 masks. Non-medical cloth masks are often home-made and oftenrecommended through such conduits as the media as being a good, safepreventative measure against such viruses as Covid-19 but should only beused as a last resort. In addition the fit is never good so that leakageof air from the outside through the sides of the mask making these maska problem, as well as giving the user a false sense of safety whichcould result in the user taking risks that they would not ordinarilytake. Surgical or medical masks are a step up from cloth masks and aregenerally disposable and considered to be barriers to large aerosolparticles that contain viruses. The N95 masks are considered to be thebest with a “tight fit” although significant training is necessary toensure a tight fit. (See FIG. 2). They are rated to screen out 95% ofsmall airborne particles such as those suspended in mists that carrier avirus. As can be seen the best masks only filter our 95% of theinfectious particles. While there are masks that are rated to remove99+% of particles from the air, they can still allow viruses through(See FIG. 1). Utilizing a valve on these masks is also ineffective asthe lack of seal will not adequately activate a valve.

More effective masks utilize a silicone seal around the mouth and noseand generally have two intake filters with one-way valves and an exhaustvalve with no filter for exhale. They can also be full face to cover theeyes for better protection. There are several problems with this design.One, the mask protects the user from outside microbes via the intakefilters, but it does not protect the outside population from an infecteduser. Two, microbes will collect on the outside of the filter which cancontaminate the user by physical contact with the mask. Three, in thecase of filter imperfections, there is no redundancy system to preventcontamination of the user.

It is well documented that filters do not act as sieves. The filtersused in modern surgical masks and respirators are considered “fibrous”in nature—constructed from flat, nonwoven mats of fine fibers. Fiberdiameter, porosity (the ratio of open space to fibers) and filterthickness all play a role in how well a filter collects particles. Inall fibrous filters, three “mechanical” collection mechanisms operate tocapture particles: inertial impaction, interception, and diffusion.Inertial impaction and interception are the mechanisms responsible forcollecting larger particles, while diffusion is the mechanismresponsible for collecting smaller particles. In some fibrous filtersconstructed from charged fibers, an additional mechanism ofelectrostatic attraction also operates. This mechanism aids in thecollection of both larger and smaller particle sizes. This lattermechanism is very important to filtering facepiece respirator filtersthat meet the stringent NIOSH filter efficiency and breathing resistancerequirements because it enhances particle collection without increasingbreathing resistance.

It is also well known that an increase in respiration rated reduces theeffectiveness of filtration as the velocity of the particle entering themask is increased thereby altering the usefulness of some of themechanism by which the filter works. (See FIG. 3).

The best filters commercially available are considered to be HEPAfilters, which remove particles down to 0.1 μ. While helpful, it hasbeen found that certain viruses, such as Cociv-19 can range below 0.1 μto about 0.06 μ rendering such filter as ineffective.

Based on the foregoing it is an unmet need to obtain improvedanti-microbial breathing apparatus that is more effective and efficientand address the shortcomings of the currently available breathingsystem, in particular, addressing the viral particles that do getthrough the system.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 shows a chart the particle blocking capability of various masks.

FIG. 2 shows a chart of the fit ability of various masks.

FIG. 3 shows a chart of the increase in particle penetration as afunction of respiratory volume.

FIG. 4A shows a front view and cutaway of an embodiment of the currentdisclosure.

FIG. 4B shows a side view cutaway of an embodiment of the currentdisclosure.

FIG. 5 shows an embodiment of the attachment mechanism for removablyattaching a module of the current disclosure to a breathing apparatus.

FIG. 6 shows an embodiment of the current disclosure, including filters.

FIG. 7 shows an embodiment of the current disclosure includingsanitizing bulbs.

FIG. 8A shows a side view cutaway of a cylindrical embodiment of thecurrent disclosure further utilizing air valves.

FIG. 8B shows an end view of the cylindrical embodiment with circularbaffles 66 and 67.

FIG. 9 shows an embodiment of the current disclosure utilizing to aid inthe intake of ambient air as well as filters and removable reflectiveinsert.

FIG. 10 shows an embodiment of the current disclosure wherein modulesare removably attached to a breathing apparatus.

SUMMARY OF THE DISCLOSURE

It is an object of the current invention to overcome the deficienciescommonly associated with the prior art as discussed above and providesterilizing modules, devices and methods that eliminate or deactivateundesirable pathogenic microorganisms from entering the body of a userof the devices.

In a first embodiment, disclosed and claimed herein are anti-microbialsterilizing modules comprising at least one sterilizing radiationemitting component, wherein the sterilizing module is configured to beremovably attached to a breathing device.

In a second embodiment, disclosed and claimed herein are anti-microbialsterilizing breathing modules of the above embodiment wherein thebreathing device to which the sterilizing module is removably attachedis a wearable mask.

In a third embodiment, disclosed and claimed herein are anti-microbialsterilizing breathing modules of the any of the above embodimentswherein the sterilization module comprises an air intake port throughwhich ambient air may enter the sterilizing module, an elongated pathinternal to the sterilizing module through which the ambient air maytravel, at least one sterilizing radiation emitting component situatedinternal to the sterilizing module and, an exit port through which theambient air may enter the mask, wherein the sterilizing radiationemitting component irradiates the ambient air when travelling throughthe sterilizing module.

In a fourth embodiment, disclosed and claimed herein are anti-microbialsterilizing breathing modules of any of the above embodiments whereinthe at least one sterilizing radiation emitting component emits bluelight, UV light, UVC light or combinations thereof and the interior ofthe sterilizing module through which air passes is fully or partiallyreflective of the sterilizing radiation.

In a fifth embodiment, disclosed and claimed herein are anti-microbialsterilizing breathing modules of any of the above embodiments furthercomprising filters situated on or in the sterilizing module, on or inthe breathing apparatus, or both, and wherein the filters are optionallyreplaceable.

In a sixth embodiment, disclosed and claimed herein are anti-microbialsterilizing breathing modules of any of the above embodiments furthercomprising intake and outflow valves.

In a seventh embodiment, disclosed and claimed herein are anti-microbialsterilizing breathing modules of any of the above embodiments whereinthe sterilizing module is self-powered and configured to be poweredexternally.

In an eighth embodiment, disclosed and claimed herein are anti-microbialsterilizing breathing modules of any of the above embodiments whereinthe elongated path is a linear path with optional 180 corner bends, acircular path wherein air that is taken in flows around circularbaffles, a spiral path or a rectangular path having at least one intakeand/or at least one outflow valve which regulates the intake and outflowof air in the module.

In a ninth embodiment, disclosed and claimed herein are anti-microbialsterilizing breathing modules of any of the above embodiments whereinbaffles made of UVC transparent material are arranged internal to thesterilizing module which are configured to direct the intake air to movethrough the sterilizing module, wherein the baffles allow UVC to passthrough the baffles when directing the air intake through thesterilizing module.

In a tenth embodiment, disclosed and claimed herein are anti-microbialsterilizing breathing modules of any of the above embodiments furthercomprising a metallic screen situated internal to the sterilizationmodule.

In a eleventh embodiment, disclosed and claimed herein areanti-microbial sterilizing breathing modules of any of the aboveembodiments further comprising at least one baffle situated internal orexternal to the sterilizing module, configured to prevent sterilizingradiation from exiting the sterilizing module and further comprising afan configured to move air into the sanitizing module.

DESCRIPTION OF THE INVENTION

As used herein, the terms “having”, “containing”, “including”,“comprising” and the like are open ended terms that indicate thepresence of stated elements or features, but do not preclude additionalelements or features. The articles “a”, “an” and “the” are intended toinclude the plural as well as the singular, unless the context clearlyindicates otherwise.

As used herein, the conjunction “and” is intended to be inclusive andthe conjunction “or” is not intended to be exclusive unless otherwiseindicated. For example, the phrase “or, alternatively” is intended to beexclusive.

As used herein, the term “and/or” refers to any combination of theforegoing elements including using a single element.

As used herein the term “breathing apparatus” includes such devices asmasks, ventilators, breathing tubes, of other devices that aid inassisting the deliverance of air to a person or animal.

As used herein the term UVB refers to electromagnetic radiation withwavelengths ranging between about 280-315 nanometers, inclusively.

As used herein the term UVC refers to electromagnetic radiation withwavelengths ranging between 100-280 nanometers, inclusively.

In response to the long-needed improvement of personal protectionequipment, especially the need for improved breathing apparatus tocombat past, present, and future viruses and other pathogens, a newinventive sterilizing module is provided for the destructive and/or atleast deactivation of such pathogens. The innovative sterilizationmodule which receives ambient air from the outside of the sterilizingmodule through one or more intake ports and through the action of theuser's breathing, pulls the air through an elongated path in thesterilizing module and out of the sterilizing module through one or moreexit ports. In some embodiments, where necessary, a mechanical assistmay be present which helps to pull or push the air into the sterilizingmodule and through the sterilizing module out to the user. The nowsterilized air passed out the at least one exit port of the sanitizingmodule and enters the remainder of the breathing apparatuses such as,for example, a mask.

The sterilization module contains one or more electromagnetic radiationemitting components, such as, for example, LEDs, mercury vaporfluorescent bulbs, filament bulbs and lasers.

Since it is well known that pathogens, such as, for example, viruses,bacteria, molds, mildews and the like, can be destroyed or at leastdeactivated when exposed to certain wavelengths of electromagneticradiation, one or more radiation emitting components are arranged invarious positions internal to, that is throughout the interior of, thesterilizing module. The radiation emitting components can emit bluelight radiation, UVB radiation or UVC radiation each of which is knownto destroy or deactivate various pathogens. The sterilizing module maycontain components that only emit in one sterilizing radiation range, orthere can be a combination of components that emit in any of the blue,UVB and UVC radiation ranges.

As the air passes through one or more intake ports and through thesterilization module, the radiation emitting components sterilize theair prior to exiting the sterilization module and entering the remainderof the breathing device and prior to entering the body of the user. Thedevices are configured to be useful for either a human or an animal.

Breathing apparatuses useful for the current disclosure include, forexample, masks, ventilators, breathing tubes, of other devices that aidin assisting the deliverance of air to a person or animal. Each of theseapparatuses useful for the current disclosure are configures to beremovably attached to the currently disclosed sterilizing modules. Insome embodiments the sterilizing module is removably attached to a mask,wherein the mask is wearable so that in toto the weight of thecombination mask and sterilizing module are less than about 2 pounds.The sterilizing module is detachable which allows for cleaning,replacement, maintenance, repair or other desired activity.

The sterilizing module is configured to have an elongated path throughwhich air flows and becomes sanitized, as pathogens are destroyed ordeactivated. The path may take a variety of configurations such as, forexample a straight passageway or a passageway the runs straight thenbends at a 180° angle, the angle being anywhere along the axis of thepassageway (See FIG. 4). The straight passageway may have bends at morethan one angle in order to provide extended distances through which theair travels. The angles can be any angle, such as, for example, 45°,90°, 135°, 180° or the like. Increased pathway distances provide anincrease in the amount of sanitizing radiation available for sanitizingthe incoming and exiting air. The elongated path may also be acombination of any of the above described pathways. In any of theseconfigurations sanitizing radiation components are situated internal tothe pathway and throughout the length of the elongated pathway. Themodule may be of any suitable 3-dimensional shape, such as, for example,cubic, cuboid, cylindrical, prismatic, conic, pyramidal and the like.The elongated path of the sterilizing module may take on otherconfigurations such as, for example, circular, spiral, straight, as wellas combinations.

The interior of the sterilizing module is fully or partially reflectiveof the sterilizing radiation. The sterilizing module may be fabricatedfrom sanitizing radiation reflective material or the interior of thesterilizing module may have sanitizing radiation reflective materialapplied to the interior surfaces of the sterilizing module. Applicationmay be CVD, coated or laminated and the like. Materials suitable forreflecting sanitizing radiation generally depend on the sanitizingradiation used. Materials that reflect blue and UVB radiation are wellknown in the industry, such as, for example, aluminum. Materials thatreflect UVC radiation include aluminum foil, sputtered aluminum,stainless steel, chrome coating and e-PTFE (expandedPolytetrafluoroethylene). There is no limit to the layout of theelongated path in the sterilizing module. With the selected arrangementof baffles within the sterilizing module an infinite number of layoutsmay be obtained.

The sterilizing module may also contain one or more metal screenspositioned throughout the interior of the sterilizing module. The metalscreen is configured to capture droplets of moisture which can carryvarious pathogens. The screen can be configured in the sterilizingmodule to allow sanitizing radiation to expose the droplets and attackany pathogens present. The screen may also be fabricated from metals andalloys which are known to aid in the destruction, deactivation, orreduction in activity of pathogens.

The sterilizing modules may also include one or more filters of varioustypes well known in the industry for filtration, such as, for example,filter material used in surgical masks and other filter materialdesigned for microbial environments. The filters may be positioned atthe front, back, or both and throughout both the sterilizing module andoptionally through the remainder of the breathing apparatus to which thesterilizing module is removably attached. Additional filters may beincluded in the sterilizing modules that are capable of beingelectronically charged, such as, for example, metallic screens orscreens that contain a layer of conductive materials such as, forexample, metal, conductive polymers, graphene materials and the like.The screen may be made of materials which are reflective of thesanitizing radiation to allow the radiation to be directed throughoutthe module. It is known that in some cases viruses or other pathogensare transferred primarily through aerosol moisture. Electrified screenscan attract aerosols which are generally known to carry a polarity. Bycharging a screen the aerosol particles can be attracted to the screenand remain there during operation helping to allow sanitizationradiation to sanitize the droplets

The modules of the current disclosure may be configured to bedisassemble for cleaning, component replacement, ease of storage orother purposes. The module may be made in various parts and assembledwith gasket which are constructed to provide sealing of the module toprevent air from entering the module at any point other than the desiredopening designed to direct the incoming air into the module forsanitization, or from air leaving he module at any point other than theexit provided by the module.

The sterilizing module also contains baffles at the intakes and outflowport which are configured to cover the openings of the ports to preventsterilizing radiation from exiting the sterilization module.

The sterilization module may have least one intake valve, at least oneoutflow valve, or both to regulate the intake and outflow of air in thesterilization module. The intake valve is configured to open when air istaken in and closed when air is exhaled from the used. The outflow valveworks in tandem with the intake valve so that when the user exhales, theoutflow port opens to allow air to exit, while the intake valve closes.In certain embodiments only an outflow port is present. In thisconfiguration, no air is allowed to enter through anywhere but theintake port or pots so that all inspired air is subject tosterilization.

In some embodiments a fan is present configured to aid in the intake ofambient air. The fan may also act as a positive laminar flow devicewhich provides positive pressure so that the intake of air at theinterface of a mask or other loosely fitted breathing devices iseliminated or significantly reduced.

The sterilizing module of the current disclosure is configured to beself-powering using batteries, rechargeable batteries, or othercomponents well known in the art to provide self-powering. In someembodiments there may also be included electronic connection in thosecases where external power is necessary, such as in an emergency. Themodule may further contain a power control configured to increase ordecrease power to the sterilizing radiation emitting components of thesterilizing module thus providing weaker or stronger sterilizingradiation to air coming into and through the sterilization module. Incertain environments there may be higher risks of infection so thathigher amounts of sanitizing radiation is required.

Moving now to the Figures. FIG. 1 shows a chart which compares andcontrasts the efficiency of filtering masks. As can be seen cloth masksfilter about 28% of particles while surgical masks improve to about 80%.The best masks available are dust respirators which contain 2 largecartridges on each side and are heavy and unwieldly and are only98-99.5% efficient. FIG. 2 shows the results of a number of testsperformed to determine the ability of a mask to fit properly and notallow particles to enter the mask from the mask-user interface. Also,the chart shows how different people fit the same mask. Specificinstructions are needed to get a fit. FIG. 3 shows the effect of heavybreathing on the efficacy of N95 mask, mask that are touted as the bestmasks available for consumer use. As can be seen, heavy breathingessentially doubles the number of particles that are allowed through.Couple than with an expected increase in particles entering from themask-user interface, due to a less than perfect fit, and these masks inthis situation are less than ideal.

FIG. 4 depicts one embodiment of the current disclosure. FIG. 4A is afront view of the anti-microbial sterilizing module 10. Ambient air 14enters the interior of the module 11 through opening 12, which includesa UV blocking cover, not shown. UVC/UVB emitting LEDs 20 and blue lightemitting LEDS 22 are positioned inside the module to sanitize the air asit passes though the module. An on/off switch 16 is positioned in themodule to allow turning the module on and off. A hi/low switch is alsopositioned in the module to allow for manipulation of the strength ofthe sanitizing radiation chosen by the user to respond to varyingconditions wherein there may be higher or lower risks of microbialcontamination. In this manner the battery power from the battery 24 maybe preserved. FIG. 4A provides a cut-away side view of theanti-microbial sanitizing module. Ambient air 14 enters the interior ofthe module 39 through portal 12, and around the UV blocking cover. Theair passes around baffles 35 and through the internal path 38 whileUVC/UVB/Blue radiation LEDs 30 irradiate and sanitize the air. Theinterior of the module is fully or partially fabricated from, or atleast covered with, UVC/UVC/Blue radiation reflecting materials asdescribed above. The sanitized air then exits the module through an exitport 32 which is configured to removably attached to any type ofbreathing apparatus suitable and configured to receive the module.

FIG. 5 is an embodiment of an attachment socket of the currentdisclosure wherein the exiting air 42 passes through an opening in thewall of the module 43 and through an opening in the attachment wing 44.In addition, FIG. 5 shows a baffle 12 which blocks sanitizing radiationfrom exiting the module while at the same time is offset to allow air tobe taken in and let out.

FIG. 6 depicts a further embodiment of the current disclosure whereinfilters are arranged in the module to in filtering out dust or otherharmful particles including some microbial materials. As depicted,ambient air 46 passes through a filter 45, such as, for example, a HEPAfilter, and into the interior of the module 47. More than one filter maybe positioned in this embodiment. Again baffles 48 are present toincrease the path of the air allowing increased residence time of theair to be exposed to sanitizing radiation from sanitizing-radiationemitting LEDs 49. The sanitized air may then optionally pass through 51another filter 50 prior to entering the breathing device to which themodule is removably attached. Again, more than one filter may positionhere. Also shown in FIG. 6 is the embodiment wherein a further filter isincluded 45A which is metal screen (filter) which is electronicallycharged.

FIG. 7 depicts another embodiment of the current disclosure. Ambient air54 passes through one or more filters 52 into the interior 53 of themodule. The air passes around baffles 55 and exits though an exit port57. In this embodiment a sanitizing radiation lamp 56 is positioned tosanitize the air.

FIG. 8 depicts a cylindrical module of the current disclosure which alsoincludes intake valves. FIG. 8A depicts a cutaway side view of thecylindrical embodiment wherein the ambient air 62 enters the sanitizingmodule 65 through air intake valves 60. The air then passes aroundcircular baffles 66 and 67. The air is irradiated with sanitizingradiation from sanitizing-radiation emitting bulb 63. The bulbs arecovered with radiation blocking caps 64 to prevent radiation fromleaking outside the module. The sanitized air then exits the modulethrough an exit port. FIG. 8B depicts an end view of the cylindricalembodiment showing the circular nature of the baffles and overall moduleconfiguration.

FIG. 9 depicts an embodiment of the current disclosure which includes afan for aiding in the passage of ambient air into and through themodule. Ambient air 76 is drawn into a cavity 73 by a fan 70. The air 77then passes through a filter 72 into the interior of the module 71. Theair then travels around baffles 75 while sanitizing radiation from LEDs74 sanitize it. The sanitized air 81 then exits through a filter 79. Thesanitizing module is powered by battery and electronics 80. In thisembodiment the baffles 75 are an insert which can be removed formaintenance and other purposes.

FIG. 10 depicts a sanitizing breathing apparatus utilizing thesanitizing modules of the current disclosure. Two sanitizing modules 92are removably attached to a breathing apparatus, in this case a mask forwearing on the face to cover nose and mouth. The mask includes straps 95for application. The mask also has an optional filtering port.

As can be seen from the foregoing discussion and the figures the currentdisclosure can take on many configurations.

We claim:
 1. An anti-microbial sterilizing module comprising at leastone sterilizing radiation emitting component, wherein the module isconfigured to be removably attached to a breathing device.
 2. Theanti-microbial breathing module of claim 1, wherein the breathing deviceto which the module is removably attached is a wearable mask.
 3. Themodule of claim 2 comprising: a. At least one air intake port, throughwhich ambient air may enter the module, b. an elongated path internal tothe module through which the ambient air may travel, c. at least onesterilizing radiation emitting component situated internal to the moduleand, d. at least one exit port through which the ambient air may enterthe mask, wherein the sterilizing radiation emitting componentirradiates the ambient air when travelling through the module.
 4. Themodule of claim 3, wherein the at least one sterilizing radiationemitting component emits blue light, UV light, UVC light or combinationsthereof and the interior of the sterilizing module through which airpasses is fully or partially reflective of the sterilizing radiation. 5.The module of claim 4 further comprising at least one filter situated onor in the module, on or in the breathing apparatus, or both.
 6. Themodule of claim 5 further comprising a filter comprised of a conductivemetal wherein the filter comprised of a conductive metal is configuredto be electrically chargeable.
 7. The module of claim 4 furthercomprising intake and outflow valves.
 8. The module of claim 4, whereinthe sterilizing module is self-powered and configured to be poweredexternally.
 9. The module of claim 5, wherein the at least one filter isreplaceable.
 10. The module of claim 3, wherein the elongated path is alinear path with optional 180 corner bends, a circular path wherein airthat is taken in flows around circular baffles, a spiral path or arectangular path.
 11. The module of claim 4 further comprising a fanconfigured to move air into the sanitizing module.
 12. The module ofclaim 4, wherein baffles made of UVC transparent material are arrangedinternal to the module which are configured to direct the intake air tomove through the module, wherein the baffles allow UVC to pass throughthe baffles when directing the air intake through the module.
 13. Themodule of claim 4 further comprising a metallic screen situated internalto the sterilization module wherein the metal screen is configured to beelectrically chargeable.
 14. The module of claim 4 further comprising atleast one baffle situated internal or external to the module, configuredto prevent sterilizing radiation from exiting the module.
 15. The moduleof claim 4, further comprising at least one intake valve and at leastone outflow valve.
 16. The module of claim 4, further comprising a powercontrol configured to increase or decrease power to the sterilizingradiation emitting components of the sterilizing module.
 17. The moduleof claim 4 wherein the module is configured to allow disassembly.